Oilon Junior Pro 1 J10 Manual

OPERATING AND MAINTENANCE
INSTRUCTIONS FOR LIGHT OIL
BURNERS
Burners without preheating
Junior Pro 1
J10
J18
Junior Pro 2
J20
J45
J50
Burners with preheating
Junior Pro 1
LJ10
LJ18
Junior Pro 2
LJ20
LJ45
LJ50
Read these instructions carefully before installation, commissioning or maintenance of
the burner!
OILON HOME OY
P.O. Box 5, 15801 Lahti
Visiting address:
Tarmontie 4,
15860 Hollola
Tel. [phone]
fax [phone]
[email protected]
www.oilon.com
10090943EN

10090943EN
Table of Contents
1. Conventions in this Manual............................................................................................................1
2. General ..........................................................................................................................................2
3. Burner Technical Data ...................................................................................................................4
3.1. Exploded View (Junior Pro 1 LJ10) .....................................................................................4
3.2. Parts List ..............................................................................................................................5
3.3. General ................................................................................................................................7
3.4. Capacity Table.....................................................................................................................7
3.5. Name Plate ..........................................................................................................................8
4. Burner Installation ..........................................................................................................................9
4.1. Burner Mounting ..................................................................................................................9
4.2. Hinged Burner Housing .....................................................................................................10
4.3. Electric Connections ..........................................................................................................10
4.4. Connecting the Burner to the Mains ..................................................................................10
4.5. Connecting the Burner to Oil Supply Line .........................................................................11
5. Fuel System .................................................................................................................................12
5.1. Oil Pipes.............................................................................................................................12
5.2. Oil Pumps ..........................................................................................................................13
6. Burner Operation..........................................................................................................................14
6.1. Operating Scheme, Oil Pump BFP 21 L3..........................................................................14
6.2. Operating Scheme, Oil Pump AS 47C ..............................................................................14
6.3. Burner Operation Principle ................................................................................................15
7. Burner Adjustment .......................................................................................................................17
7.1. Capacity Regulation...........................................................................................................17
7.1.1. Nozzle Selection ...................................................................................................17
7.1.2. Oil Pump Pressure Regulation .............................................................................18
7.1.3. Calculation of Burner Capacity ............................................................................18
7.2. Nozzle Table ......................................................................................................................19
7.3. Nozzle and Ignition Electrode Settings..............................................................................20
7.4. Change of nozzle...............................................................................................................20
7.5. Adjusting the Air Velocity in the Combustion Head J50, LJ50 ..........................................21
7.6. Adjusting the Distance and Centrality of the Nozzle .........................................................22
7.7. Combustion Air Adjustment ...............................................................................................23
7.8. Flame Inspection ...............................................................................................................24
8. Control Unit BHO 64.A/LOA 24.173A27 ......................................................................................25
8.1. Time Sequence Diagram (Control Program).....................................................................25
8.2. Control Functions in the Event of Faults............................................................................26
8.3. Technical Data of Control Unit...........................................................................................26
8.4. Current through Flame Detector........................................................................................26
8.5. Measurement of Flame Signal...........................................................................................27
9. Maintenance.................................................................................................................................28
10. Fault Conditions and Procedures.................................................................................................29
Electric diagrams

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1. Conventions in this Manual
Read these instructions carefully before installation, commissioning or
maintenance of the burner. The given instructions must be followed.
Throughout this manual, the following three symbols are used to point out very
important information:
WARNING! A warning alerts you to possible danger to person, if the instructions are
not followed.
CAUTION! A caution alerts you to something, that has the potential to cause damage
to component, burner, process or surroundings, if the instructions are not followed.
Note! A note points out information of special interest.
KEEP THESE OPERATING AND MAINTENANCE INSTRUCTIONS
AS WELL AS THE ELECTRICAL SCHEMES AVAILABLE NEAR
THE BURNER!

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2. General
Oilon Junior Pro burners are fully automatic light oil burners.
The burners can be used on most heating appliances such as hot water boilers, steam boilers
and air heaters.
A fan attached to the burner and dimensioned to provide a sufficiently high and even air
pressure for efficient combustion in modern combustion chambers supplies the required air.
The burners are suitable for use on fuel oil (light fuel oil), with a viscosity of 4 - 6 mm²/s (cSt) at
a temperature of +20 °C.
The oil supplied to the burner must be filtered before the burner oil pump. Filtration degree is
from 20 - 40 μm. We recommend mounting of an Oilon Plus filter and deaerator unit.
Oil atomizing pressure 800 - 1400 kPa (8 - 14 bar). Factory setting approx. 10 bar.
”LJ” burners are equipped with a preheater.
Required combustion air quantity: 15 m³ combustion air for each burnt kg of oil.
Burner operation is controlled and monitored by the burner automation.
Boiler thermostats or pressurestats control the burner capacity.
Burner protection: IP20
Supply voltage 230 V (-15 %...+10 %) 50 Hz 1-phase
Consumption: approx. 135 W, 0,71 A, 230 VAC, 50 Hz, 1-phase (J10, J18, J20, J45, J50)
approx. 220 W, 1,0 A, 230 VAC, 50 Hz, 1-phase (LJ10, LJ18)
approx. 330 W, 1,7 A, 230 VAC, 50 Hz, 1-phase (LJ20, LJ45, LJ50)
The ambient temperature during burner operation must be +8...+40 °C.
The following should be checked before first start-up:
•connections are correct
•settings of boiler regulating and control devices are correct
•boiler and its equipment are in working condition
•boiler room is adequately ventilated
•valves in supply lines are open
•there is oil in the tank
•oil temperature is adequate so that the viscosity is 4 - 6 mm²/s (max. +60 °C).

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CAUTION! The burner must be installed firmly. Vibrations may damage burner or its
components.
CAUTION! Disconnect the plug connector before burner maintenance or removal from
the boiler. See chapter ”Connecting the Burner to the Mains”.
WARNING! In case of fire or other danger:
- switch off the main switch
- close the main fuel shut-off valve outside the plant
- take appropriate actions.
WARNING! Never use a naked flame while checking the burner or the boiler. Never
store any inflammable material in the boiler room.
WARNING! Keep the boiler door closed while starting the burner and during burner
operation.
Correct installation and adjustment together with regular servicing are the most reliable
guarantees of trouble-free burner operation.
Note! Local regulations and requirements must be adhered to when installing or servicing
the burner.
When ordering spare parts please give the burner type and serial number indicated on the
burner nameplate.

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3. Burner Technical Data
3.1. Exploded View (Junior Pro 1 LJ10)

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3.2. Parts List
PCs
1 Burner housing 1
2 Name plate 1
3 Gasket 1
4 Hinge pin 2
5 Fixing screw for combustion head 3
6 Combustion head 1
J10
J18
J20
J45
J50 with adjustment ring
7 Fixing screw for mounting flange
M10 x 25 2 and/or
M8 x 25 4
8 Mounting flange 1
9 Flange gasket 1
10 Air adjustment ring 1
Pro 1: 1/2-opening
Pro 2: 1/1-opening
11 Fixing nut for adjustment ring 1
12 Air cone 1
13 Fixing screw for air cone 3
14 Fixing screw for fan wheel 1
15 Fan wheel 1
Pro 1: Ø 120 x 52
Pro 2: Ø 133 x 52
16 Motor 1
17 Fixing screw for oil pump 3
18 Plug connector for motor 1
19 Fixing screw for motor 4
20 Oil pump coupling 1
21 Plug connector for oil pump 1
22 Nipple for pressure pipe 1
23 Oil pump 1
24 Cover plate for motorbox 1
25 Motorbox 1
26 Fixing screw for motorbox 2
27 Grommet for preheater cable 1
28 Flame detector (photo resistor) 1
29 Holder for flame detector 1
30 Plug connector, socket 1
31 Fixing screw for socket 2
32 Plug connector, plug-in part 1
33 Limit switch 1
34 Fixing screw for limit switch 2
35 Limit switch cable 2
36 Air setting scale 1
37 Fixing screw for air setting 1
38 Fixing screw for air setting scale 1
39 Cable sleeve for ignition cable 2
40 Ignition transformer 1
41 Plug connector for ignition transformer 1
42 Fixing screw for ignition transformer 2
43 Self-closing air flap 1
44 Front plate 1
45 Insulation for air intake 1

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PCs
46 Air intake 1
47 Fixing screw for air intake 4
48 Clamp for run hour counter, optional extra 1
49 Locking nut for grommet 1
50 Grommet 3
51 Fixing screw for control unit bracket 1
52 Control unit bracket 1
53 Signal lamp indicating readiness for operation 1
54 Baseplate for control unit 1
55 Fixing and earth screws for control unit 3
56 Control unit 1
57 Run hour counter, optional extra 1
58 Fixing screw for ignition electrode holder 1
59 Ignition electrode holder 1
60 Nozzle 1
61 Preheater + nozzle conduit 1
Pro 1: FPHB5
Pro 2: FPHB10
/ Nozzle holder + nozzle conduit, without preheating
62 Fixing screw for nozzle conduit holder 1
63 Nozzle conduit holder: 1
J10, J18, J20, J45, J50, LJ10, LJ18: Ø 10
LJ20, LJ45, LJ50: Ø 18,5
64 Cover plate 1
65 Eccentric piece 1
66 Locking screw for eccentric piece 1
67 Ignition electrodes 1
68 Ignition electrode holder 1
69 Locking screw for ignition electrode holder 1
70 Sight glass 1
71 Plug connector for preheater 1
72 Protective sleeve for ignition cable nipple 2
73 Ignition cable 2
74 Fixing screw for cover plate 2
75 Pressure pipe 1
76 Gasket ring for oil hose nipple 2
77 Nipple for oil hose 2
78 Oil hose 2
79 Nipple for oil hose 2
80 Filter cover 1
81 Bracket for filter 1
82 Filter 1

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3.3. General
•burner types:
• without preheating
Junior Pro 1
J10
J18
Junior Pro 2
J20
J45
J50
• with preheating
Junior Pro 1
LJ10
LJ18
Junior Pro 2
LJ20
LJ45
LJ50
•the burner can be hinged to both sides
•the standard burner must be installed in such a position, that the motor shaft lies
horizontally; but the burner must not, however, be installed upside down. In the case the
burner must be installed upside down, a separate installation set with instructions must be
ordered from the manufacturer.
•burner control unit internally connected
•safety switch (limit switch) on the hinged burner housing
•stepless adjustable air regulation
•oil pump atomizing pressure 800 - 1400 kPa (8 - 14 bar), factory setting approx. 10 bar
•electrical connection with a plug connector
•standard equipment for two pipe system
•recommended nozzle types:
- solid 45° - 60° (Junior Pro 1 J10, J18, LJ10, LJ18)
- solid 60° (Junior Pro 2 J20, J45, J50, LJ20, LJ45, LJ50)
•NOx-class 2
Optional extra
•boiler dual thermostat
- regulating thermostat max. 95 °C
- limit thermostat 100 °C
•pocket for thermostat
•run hour counter
•deaerator Tigerloop
•oil flow meter
•Oilon Plus filter and deaerator unit:
- filter
- deaerator
- pressure gauge
- protective cover
- multi-function meter, optional extra

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3.4. Capacity Table
Burner Burner capacity range
kg/h kW
Junior Pro 1
J10 1,4 - 2,3 17 - 27
J18 1,7 - 2,8 20 - 33
Junior Pro 2
J20 2,3 - 4,1 27 - 48
J45 3,0 - 4,8 36 - 57
J50 2,3 - 6,5 27 - 77
Junior Pro 1
LJ10 1,4 - 2,3 17 - 27
LJ18 1,7 - 2,8 20 - 33
Junior Pro 2
LJ20 2,3 - 4,1 27 - 48
LJ45 3,0 - 4,8 36 - 57
LJ50 2,3 - 6,5 27 - 77
Burner capacities are achieved according to standard EN267.
3.5. Name Plate
Burner type is marked with a X. Example Junior Pro 1 LJ10.
Use only original spare parts. When ordering spare parts please give burner type and serial number
indicated on the burner nameplate.

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4. Burner Installation
4.1. Burner Mounting
The furnace, which has a flame-shaped design, does not require refractory. Boilers without
bottom cooling require refractory to prevent heat from reaching boiler foundations.
The flame must at no point come into contact with the furnace walls. If this cannot be avoided,
such points must be covered with refractory. This applies especially to the refractory at the back
wall of short furnaces.
1 Mounting plate 5 - 7 mm
2 Gasket 3 - 5 mm
3 Thermal insulation
approx. 50 mm
The mounting plate must have either two M10 threaded holes or four M8 threaded holes for the
mounting of the burner according to the drawing.

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4.2. Hinged Burner Housing
As standard the burner can be hinged to both sides.
4.3. Electric Connections
The burner must be connected according to the electrical diagrams delivered together with the
burner. General and local standards and regulations as well as requirements of electrical
equipment on electrical connections must be adhered to.
4.4. Connecting the Burner to the Mains
Electrical connection on burner is with a plug connector. Connect the cable of the plug supplied
with the burner to the boiler thermostat or pressurestat. The socket has been firmly attached to
the burner housing. Disconnect the burner from the mains (burner switch in position 0) by
pressing the locking button and pulling out the plug from the socket at the same time.
1 Socket (fixed on the burner
housing)
2 Locking button
3 Plug (pull-out part)

CAUTION! Disconnect the plug connector before burner maintenance or removal from
the boiler.

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4.5. Connecting the Burner to Oil Supply Line
The burner is equipped for two-pipe system.
Two-pipe system
The piping must be done for two-pipe system according to the drawing, if no Oilon Plus -filter
and deaerator unit is used. Two-pipe system has both suction and return lines for fuel oil to the
tank.
1 Shut-off valve
2 Oil filter lock
3 Oil filter
4 Suction hose
5 Oil pump
6 Return hose
7 Shut-off valve/non-return valve
A-A Delivery limit
Oilon Plus filter and deaerator unit
We recommend use of an Oilon Plus filter and deaerator unit, where the oil flows from the tank
in one pipe to the unit. The oil pump is connected as in two-pipe system. The by-pass plug must
be fixed in the oil pump. The pressure gauge of the unit indicates if the filter possibly clogs.
1 Oilon Plus filter and deaerator
unit
2 Suction hose
3 Oil pump
4 Return hose
5 Siphonage stop valve,
optional extra
A siphonage stop valve is
necessary, if the oil level in the
tank lies higher than the filter and
deaerator unit
Filter
The filter should be changed in a two-pipe system at intervals of 1 - 1,5 years. If an Oilon Plus
filter and deaerator unit is used, the time of use is longer.

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5. Fuel System
5.1. Oil Pipes
The oil tank and the oil pipes must be installed to avoid the risk of the oil cooling below cloud
point. The cloud point of heating oil depends on the oil quality. If the oil is allowed to cool to the
cloud point, valves and filters will block. The most suitable oil temperature is +15...+25°C.
Note! The viscosity of oil coming to the burner must be 4 - 6 mm²/s (cSt).
The maximum lengths for other viscosities can be calculated by the simple ratio of viscosities
i.e. if the table shows lengths for 5 or 6 mm²/s (cSt) viscosity, multiply the length shown in the
table by 5 or 6 and divide by the value of the new viscosity mm²/s (cSt).
Keep in mind that absolute tightness is the fundamental pre-requisite for secure operation. A
leaking suction line may cause, among other things, afterspraying of oil into the boiler. It is
advisable to use ball valves instead of needle valves.
The tables give the maximum lengths (in meters) of return and suction lines.
Overlying oil tank Underlying oil tank
H m DANFOSS BFP/MS (ø d mm) H m DANFOSS BFP/MS (ø d mm)
ø 6 mm ø 8 mm ø 10 mm ø 6 mm ø 8 mm ø 10 mm
0 17 53 100 0 17 53 100
0,5 19 60 100 0,5 15 47 100
1,0 21 66 100 1,0 13 41 99
1,5 23 72 100 1,5 11 34 84
2,0 25 79 100 2,0 9 28 68
2,5 27 85 100 2,5 7 22 53
3,0 29 91 100 3,0 5 15 37
3,5 31 98 100 3,5 - 9 22
4,0 33 100 100 4,0 6
2800 rpm, 6 mm²/s (cSt) 2800 rpm, 6 mm²/s (cSt)
H m SUNTEC 45/47 (ø d mm) H m SUNTEC 45/47 (ø d mm)
ø 6
mm
ø 8
mm
ø 10
mm
ø 12
mm
ø 6
mm
ø 8
mm
ø 10
mm
ø 12
mm
0 14 49 123 150 0 14 49 123 150
0,5 16 55 136 150 0,5 12 43 109 150
1,0 18 61 150 150 1,0 10 37 94 150
2,0 22 73 150 150 2,0 7 26 65 138
3,0 25 85 150 150 3,0 - 14 37 78
4,0 29 96 150 150 4,0 - - 8 18
2850 rpm, 5 mm²/s (cSt) 2850 rpm, 5 mm²/s (cSt)
Dmax = 20 m Hmax = 4,5 m
(D-H)max. = 4,5 m
See the oil piping dimensions from the Oilon Plus manual, if an Oilon Plus filter and deaerator
unit is used.

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5.2. Oil Pumps
Danfoss
Suntec
1. Suction line connection 6. Pressure regulation
2. Return line connection 8. By-pass plug
3. Nozzle connection 9. Filter
4. Pressure gauge connection 10 Solenoid valve coil
5. Vacuum meter connection
Oil pump venting
Two-pipe system needs no venting as the air comes away when starting the burner. In order to
speed up the air removal, nipple (4) in the pressure gauge connection can be loosened.
Removal of oil pump and pump coupling
Remove the oil pump (1) from the motor (4) by loosening three fixing screws (3) and withdraw
the oil pump. Check the condition of the oil pump coupling (2) and replace, if necessary.
1 Oil pump
2 Oil pump coupling
3 Fixing screws, 3 pcs
4 Motor
5 Fan wheel

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6. Burner Operation
6.1. Operating Scheme, Oil Pump BFP 21 L3
1 Oil filter 9 Ignition electrodes
2 Return hose 10 Solenoid valve, normally closed, NC
3 Suction hose 11 Nozzle
4 Oil pump 12 Control unit
5 Pressure pipe 13 Control device (thermostat/pressurestat)
6 Burner fan 14 Preheater, LJ-burners only
7 Burner motor 15 Flame detector
8 Ignition transformer
6.2. Operating Scheme, Oil Pump AS 47C

1 Oil filter 9 Ignition electrodes
2 Return hose 10 Solenoid valve, normally open, NO
3 Suction hose 11 Nozzle
4 Oil pump 12 Control unit
5 Pressure pipe 13 Control device (thermostat/pressurestat)
6 Burner fan 14 Preheater, LJ-burners only
7 Burner motor 15 Flame detector
8 Ignition transformer

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6.3. Burner Operation Principle
TZ Limit thermostat M1 Burner motor (fan/oil pump)
TS Regulating thermostat T1 Ignition transformer
E1 Preheater EV1 Solenoid valve
TSW Preheater thermostat B1 Flame detector/flame signal
Prerequisites for start-up
•burner is getting fuel
•failures and interlocks are reset
•contacts of switches of control voltage supply on control unit and contacts of
thermostats are closed, whereby the control voltage is applied to terminal 1 in control
unit.
A´ Start on burner with preheating
•control signal from control unit terminal 8
•preheater begins to heat up the fuel
•contact of lower limit thermostat (TSW) in preheater closes after time ”tw” (approx.
1 min), when the oil temperature has reached approx. 70 °C, whereby the control
signal is applied to terminal 3 in control unit.
A Start on burner without preheating
•control signal is applied from terminal 8 to terminal 3 in control unit
•burner motor (fan/oil pump) starts
•pre-ignition begins
•pre-purge begins.
B´ Solenoid valve receives control signal
•safety time begins (max. 10 s)
•solenoid valve opens (Danfoss) or closes (Suntec)
•atomizing of oil begins
•flame has to be ignited during safety time, otherwise control unit goes to lock-out
Required input signals to control unit
Control signals from control unit

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B Flame is established
•flame relay (FR) is energised, whereupon terminals 8 and 3 are linked. Opening of
preheater thermostat contact does not shut down the burner during flame.
•burner has started
•post-ignition 2 s (control from terminal 7).
C Control unit/burner in normal operating condition
•control program of control unit ends
•burner remains operating supervised by control unit (flame) and controlled by
regulating thermostat.
D Controlled shut-down with regulating thermostat
•burner motor stops
•solenoid valve closes
•flame extinguishes.
See chapter ”Control Functions in the Event of Faults”.